Design of High-Entropy Alloy Coating for Cavitation Erosion Resistance by Different Energy-Induced Dynamic Cyclic Behaviors

The dispute over the effect of cavitation heat on material surface intensifies the fuzziness of cavitation erosion (CE) mechanism and limits the development of protective materials. Here, an anti-CE Al 10 Cr 28 Co 28 Ni 34 high-entropy alloy (HEA) coating with single face-centered cubic (FCC), prepared by high-velocity oxy-fuel (HVOF) spraying technologies, was designed by inducing mechanical and thermal energy-induced behaviors to transform or counteract each other. The results showed that, on the one hand, this coating underwent the refinement of the average grain size from 1.22 to 1.02 μm, the increase in dislocation density from 1.28 × 10 –10 to 1.83 × 10 –10 m –2, and the martensitic transformation from FCC to body-centered cubic (BCC) under the cavitation load; on the other hand, cavitation heat could indeed induce grain growth and realize structural relaxation, which confirmed that cavitation heat acting on the material surface at temperatures theoretically above 1206.28 K also played a significant role in the CE mechanism. That is, the surface microstructure of this coating was always in a dynamic cycle during the CE process. Therefore, the coating achieved the simultaneous absorption of mechanical impact energy and thermal energy released by the bubble collapse while effectively avoiding the overenrichment of crystal defects and finally exhibited a CE resistance 2 times better than that of the classical AlCrCoFeNi HEA coating. This design concept of inducing different energy restraints or neutralization through the special response behaviors of surface microstructure provides a completely new way for the development of CE-resistant materials.